Active thermal control for stacked IC devices

ABSTRACT

Thermal conductivity in a stacked IC device can be improved by constructing one or more active temperature control devices within the stacked IC device. In one embodiment, the control devices are thermal electric (TE) devices, such as Peltier devices. The TE devices can then be selectively controlled to remove or add heat, as necessary, to maintain the stacked IC device within a defined temperature range. The active temperature control elements can be P-N junctions created in the stacked IC device and can serve to move the heat laterally and/or vertically, as desired.

TECHNICAL FIELD

This disclosure relates to integrated circuits (ICs). More specifically,the disclosure relates to multi-tiered IC devices and even morespecifically to systems and methods for active thermal control withinthe multi-tiered IC devices.

BACKGROUND

In IC technology there is a need to stack chips together to formmulti-tiered (3-D) IC devices (also referred to as multi-layered ICdevices or stacked IC devices). One challenge that arises when chips arestacked is that thermal conductivity is reduced. Thus, hot spots couldexist with little ability to move the heat away from the heat source.Because of the reduced size of stacked ICs, (substrate thickness goingfrom 100 microns to about 6-50 microns), the power density rises whilelateral thermal conductivity is reduced.

One method for increasing lateral thermal conductivity is to increasethe substrate thickness. This, in turn, negatively impacts the desiredform factor of the stacked IC device and degrades performance.

An additional challenge exists when more than two tiers are stacked. Insuch situations, the stacked IC device may contain multiple layers ofoxide, one between each pair of stacked tiers. Oxide, being a poorthermal conductor, adds to the heat dissipation problem.

There are several approaches for addressing the thermal conductivityissues. One approach positions a heat conducting layer between thetiers. Typically, heat conducting layers are metallic and thus couldinterfere with inter-layer electrical connections. Another approach usesThrough Silicon Vias (TSVs) to move the heat from an inner tier to asurface tier of the stacked IC device and then remove the heat from thesurface tier using traditional methods, such as positioning a highthermal conductivity material on the surface tier. Challenges ariseswith such a solution. For example, it is not always possible to positiona TSV at the necessary location because of circuitry layout requirementsin the various tiers.

Another approach is to circulate cooling material through the stacked ICdevice to cool the hot spots. A cooling circulation solution is costlyto manufacture and, because of the moving liquid, requires a pumpingmechanism and tight tolerances for liquid channels. Also, because ofcircuitry layout requirements, it may not be possible to “plumb” thedevice to channel the cooling material to the necessary location. Theplumbing problem could be overcome, to some extent, by forcing coolingliquid through the substrate itself, but this method is not without afurther set of problems and costs.

BRIEF SUMMARY

Thermal conductivity in stacked IC devices can be improved byconstructing one or more active temperature control devices within thestacked IC device. In one embodiment, the control devices are thermalelectric (TE) devices, such as Peltier devices. The TE devices can thenbe selectively controlled to remove or add heat as necessary to maintainthe stacked IC device within a defined temperature range or otherwisebring the stacked IC device to a desired temperature. The activetemperature control elements can be P-N junctions created in the stackedIC device and can serve to move the heat laterally and/or vertically asdesired.

The foregoing has outlined, rather broadly, the features and technicaladvantages of the present invention in order that the detaileddescription of the invention that follows may be better understood.Additional features and advantages of the invention will be describedhereinafter which form the subject of the claims of the invention. Itshould be appreciated by those skilled in the art that the conceptionand specific embodiment disclosed may be readily utilized as a basis formodifying or designing other structures for carrying out the samepurposes of the present invention. It should also be realized by thoseskilled in the art that such equivalent constructions do not depart fromthe spirit and scope of the invention as set forth in the appendedclaims. The novel features, which are believed to be characteristic ofthe invention, both as to its organization and method of operation,together with further objects and advantages, will be better understoodfrom the following description when considered in connection with theaccompanying figures. It is to be expressly understood, however, thateach of the figures is provided for the purpose of illustration anddescription only and is not intended as a definition of the limits ofthe present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention, reference isnow made to the following descriptions taken in conjunction with theaccompanying drawings, in which:

FIG. 1 is a schematic drawing of a multi-tiered IC device having a hotspot therein;

FIG. 2 shows one example of a prior art solution for relieving heat fromthe hot spot;

FIG. 3 shows one embodiment of a stacked IC device having activetemperature control in accordance with the teachings of the invention;and

FIGS. 4A through 4G show one method of manufacturing a multi-tiered ICdevice having active cooling capability in accordance with the teachingsof the invention.

DETAILED DESCRIPTION

FIG. 1 is a schematic drawing of multi-tiered IC device 10 having toptier 11 and bottom tier 12. Top tier 11 has an active circuit (face) 102and substrate (back) 101. Bottom tier 12 has active circuit (face) 103and substrate (back) 104. Faces 102/103 contain connections 108 whichserve to connect components (or terminals) such a component 109 on therespective tiers. These connections are made using connector paths, suchas path 107 and a via, such as via 106

For illustrative purposes, location 110 is thermally troubled in thisembodiment. That is, location 110 is a “hot spot” that exists, or couldexist, from time to time in stacked IC device 10. A hot spot, in thiscontext, means that as stacked IC device 10 is operating, thetemperature of the area in and around location 110 can becomeundesirably higher than other portions of tier 12. Because of thestacking of tier 11 on tier 12 and, preferably, reduced thickness ofeach tier, the lateral heat spread in tier 12 is reduced. In addition,air gap 111 can be formed between the tiers 11, 12 thereby reducingthermal flow upward from the hot spot.

As discussed above, there are a number of reasons to include coolingfunctionality or structures within a stacked IC device. But there arealso reasons for heating a stacked IC device, or portions thereof. Forexample, when designing an adaptive voltage scaling circuit, it isdesirable for the entire stacked IC device to have a uniformtemperature. Thus, if there are some localized areas of a tier in thestacked IC device that “run hot” (i.e., not a hot spot per se, but alocalized area that operates at a warmer temperature than other areas ina tier) it might be desirable or necessary to heat the cooler areas ofthe tier so that the stacked IC device has a relatively constant oruniform temperature. In some situations, initialization of a stacked ICdevice to a required temperature is desired or important. For example,sensors may need to be hot to operate and a TE could be used to reduceinitial heating time.

Additionally, selective heating and/or cooling may be required ordesirable in a stacked IC device. For example, selective heating orcooling or a combination thereof may be used to even out the temperaturegradients across silicon to alleviate stress caused by temperaturedifferentials in the substrate. Also, selective temperature control canbe used to allow the stacked IC device to operate, at least temporarily,in temperature environments that it otherwise would not be designed tooperate in.

FIG. 2 shows one example of a prior art solution for relieving heat fromhot spot 110. In this solution, TSV array 200 is positioned above hotspot 110 so that the heat flowing from the hot spot 110 can be conductedthrough face 103, across gap 111, through face 102 and out through vias201. In addition to the thermal conductivity problems, inherent withmoving the heat through the various layers and gaps, in some situationscircuitry or other elements, such as element 202, can be positioned inthe heat flow path thereby reducing (and sometimes eliminating) theeffectiveness of the TSV array 200.

FIG. 3 shows one embodiment of a stacked IC device 30 having activetemperature control in accordance with the teachings of the invention. ATE device 300 includes a pair of P-N junctions. Each P-N junctionincludes a P-type element 301 and N type element 302, as well as abottom conductor 303. Depending on which direction current flows throughthe P-N junction, the bottom conductor 303 can either attract heat orprovide heat. In one embodiment, the TE device 300 is a Peltier device.Although a pair of P-N junctions are shown, the invention is not limitedto such a configuration. Rather, more or fewer P-N junctions can beprovided.

Control circuit 304 is used to establish the current flow directionthrough the P-N junction. Control circuit 304 also controls currentdensity. Circuit 304 provides selective current control to TE device 300via an input, such as input 321. In one embodiment, a TE device 300operates such that a top side (top not designated with a referencenumber) heats while the other side, e.g., bottom 303, cools, based uponthe current direction.

The thermal energy from hot spot 110 passes up through faces 103 and 102to device 300. This thermal flow can be facilitated by constructingchannels (vias) through the faces if desired. By selecting the propercurrent density, and current flow direction, device 300 serves to removeheat, thereby cooling the stacked IC device 30. Heat sink, or other heattransfer devices, not shown, may be located on the surface of tier 11adjacent to TE device 300 to assist TE device 300 in heat removal fromstacked IC device 30. Note that the stacked IC device 30 can have TEdevices 300 provided in as many different areas as desired with some ofthe TE devices 300 injecting heat while others remove heat.

Note that while the P-N junction material is shown going all the waythrough the substrate of tier 11, in another embodiment, the P-Nmaterial partially fills the substrate, with the junction being formednear the bottom conductor 303. In this embodiment, the top portion ofeach via is filled by metallization, creating a contact within the vias.

In some embodiments, the “hot spot” can be co-located in the same layeras the cooling device thereby resulting in lateral heat displacement. Insuch a situation, a horizontal trench could be constructed in thesubstrate to laterally transfer the heat within the same substrate. Afirst portion of the trench would include P-type material and anotherportion of the trench would include N-type material.

FIGS. 4A though 4G show an exemplary method of manufacturing amulti-layered IC device having active temperature control.

FIG. 4A shows that tier 11 is stacked with respect to tier 12 and thatsome locations, such as locations 401-405 in the substrate of tier 11are filled from top to bottom with sacrificial fill material. As will beseen, an active temperature control element will be constructed atlocation 400.

FIG. 4B shows protective material 410 covering locations 401-404 inpreparation for the next step in the process. Uncovered locations 405will become standard TSVs as the process continues.

FIG. 4C shows the metallization of the uncovered locations 405A by metallayer 420 to create standard TSVs 405A. Copper or any desired metal canbe used for this purpose consistent with other elements of the stackedIC device. Thus, as shown in FIG. 4C the uncovered locations now containmetal as shown at 405A, whereas the elements 401-404 remains protectedand filled with sacrificial material.

FIG. 4D shows the removal of portions 410-2 and 410-4 of protectivematerial 410 leaving portions 410-1 and 410-3 in place. The sacrificialmaterial within vias 402 and 404 is also shown removed.

FIG. 4E shows P-type thermal electric material deposited withinlocations 402 and 404. The P-type material has not been deposited withinlocations 401 and 403 because these locations remain protected byportions 410-1 and 410-3 and thus still contain the sacrificialmaterial.

FIG. 4F shows the removal of portions 410-1 and 410-3 of protectivematerial 410 to expose vias 401 and 403. The sacrificial material isthen removed from vias 401 and 403.

FIG. 4G shows N-type thermal material deposited in locations 401 and 403thereby completing the formation of the temperature control devicewithin layer 11. Typical materials for a Peltier device are bismuthtelluride, Sb2Te3, PbTe and SiGe, but other materials, such ascrystal-phonon glass or nano material, can be used as well. Also, it ispossible to use two metals in a metal to metal junction such asCopper-Nickel. In this embodiment, Nickel fills the TSVs 401-404 andCopper is the standard metallization. Accordingly, every TSV 401-404would be a potential Peltier device. There are two advantages of thisPeltier structure. The first advantage is the masking steps for P and Ntype fill are removed. The second advantage is the density of thePeltier devices is increased as one side of the TSV 401-404 would act asthe cooling point while the other side would be the heating side. Ofcourse heat transport in the Z direction is improved while heat transferin the X and Y direction becomes more difficult.

Although the description has shown the P-type material being depositedfirst and the N-type material subsequently being deposited, the order isnot critical. That is, the N-type material could be deposited first ifit is more convenient.

It should be pointed out that the temperature differential created bythe circuit elements in the substrate can be used to drive a voltage.The voltage thus created can be scavenged, for example, to drive othercircuit elements as shown by connection 320, FIG. 3 from control circuit304. This would effectively reverse the operation of the TE device 300.The TE device 300 will cool the thermally troubled area (in FIG. 3 thatwould be hot spot 110) because heat energy is being removed from the hotspot by conversion into electrical energy. The net effect then would bethat there would be no net cooling of the stacked IC device 30 as awhole (because energy is being returned to the stacked IC device 30elsewhere) but there would be localized cooling at the “hot spot”.Consequently, overall energy savings for the stacked IC device 30results.

A Peltier device is a heat pump that requires energy to move heat fromone point to another. As the disclosed embodiments have both pointswithin the system, the heat energy is being moved from a point where itis difficult to remove (high thermal resistance) to a location where itis easer to remove so the heat is more uniformly distributed within thesystem. Thus, the total energy demand of the system is increased if thePeltier device is used to move the heat. Because the TE device caneither remove or add heat depending upon current flow direction, adevice could be used to selectively heat or cool the stacked IC device(or a portion thereof).

In one embodiment, the Peltier device is an energy scavenger: some ofthe heat generated by the stacked IC device operation can be recovered.The control system can switch the Peltier device to move heat from pointA to point B (forward bias), or point B to point A (reverse bias) orscavenge heat from a temperature difference between points A and B topower the system. The energy balance of this TE system will depend onthe efficiency of the Peltier device and the duty cycle of the system.Thus, the Peltier device can recover some energy from the overallsystem, based upon the temperature gradient within the system. In anembodiment in which more than two tiers exist, stacked Peltier devicescan be provided to improve energy scavenging efficiency. For example, acooling Peltier device could cool one tier, pumping heat to an adjacenttier. The adjacent tier could use the pumped heat to recover additionalenergy.

Although the present invention and its advantages have been described indetail, it should be understood that various changes, substitutions andalterations can be made herein without departing from the spirit andscope of the invention as defined by the appended claims. Moreover, thescope of the present application is not intended to be limited to theparticular embodiments of the process, machine, manufacture, compositionof matter, means, methods and steps described in the specification. Asone of ordinary skill in the art will readily appreciate from thedisclosure of the present invention, processes, machines, manufacture,compositions of matter, means, methods, or steps, presently existing orlater to be developed that perform substantially the same function orachieve substantially the same result as the corresponding embodimentsdescribed herein may be utilized according to the present invention.Accordingly, the appended claims are intended to include within theirscope such processes, machines, manufacture, compositions of matter,means, methods, or steps.

What is claimed is:
 1. A stacked integrated circuit (IC) devicecomprising: a tier having an active layer in which active circuits aredisposed and a substrate layer, the active layer directly on thesubstrate layer; and a thermal electric (TE) device partially disposedwithin the substrate layer and partially disposed within the activelayer in which the active circuits are disposed, the TE devicefacilitating thermal flow between an area of said stacked IC device andsaid TE device.
 2. The stacked IC device of claim 1 further comprisingat least one other tier having active circuits and a substrate.
 3. Thestacked IC device of claim 2 wherein said TE device is constructedwithin one of said tiers and wherein said area is in a tier other than atier in which said TE device is constructed.
 4. The stacked IC device ofclaim 3 further comprising: an input for receiving selective controlsignals for enabling said TE device.
 5. The stacked IC device of claim 3wherein said TE device comprises a Peltier device.
 6. The stacked ICdevice of claim 1 further comprising: at least one electrical connectionfrom said TE device to an active element in said stacked IC device so asto allow said TE device to supply power to said active element, saidpower generated from thermal flow from said area.
 7. A stackedintegrated circuit (IC) device comprising: first and second tiers, eachof the first and second tiers having an active layer in which activecircuits are disposed and a substrate layer on which the active layer isdirectly disposed; and at least one P-N junction partially constructedin at least one of said substrate layers of the tiers and partiallyconstructed within at least one of the active layers, said junctionoperable for thermal energy transfer to/from a location in at least oneof said tiers by selective application of current flow with respect tosaid junction.
 8. The device of claim 7 wherein said location is a hotspot created by elements in said stacked IC device.
 9. The device ofclaim 8 further comprising: an input for receiving selective controlsignals for enabling said P-N junction.
 10. The device of claim 8wherein said P-N junction comprises a Peltier device.
 11. The device ofclaim 7 further comprising: at least one electrical connection from saidP-N junction to an active element in said stacked IC device to allowsaid P-N junction to supply power to said active element, said powergenerated from energy provided from said location.
 12. A stackedintegrated circuit (IC) device comprising: at least two bonded tiers,each tier containing an active layer in which circuit elements aredisposed and a substrate layer on which the active layer is directlydisposed; and a thermal electric (TE) device partially constructedwithin at least one of said substrate layers of the tiers and partiallyconstructed within at least one of the active layers, the thermalelectric (TE) device being configured for selectively heating/cooling aparticular area of one of said tiers.
 13. The stacked IC device of claim12 further comprising: an input for receiving current for controllingsaid TE device.
 14. The stacked IC device of claim 12, furthercomprising a control system that controls the thermal electric device togenerate electrical energy from a temperature gradient within thestacked IC device.
 15. A stacked integrated circuit (IC) devicecomprising: a tier having an active layer in which active circuits aredisposed and a substrate layer on which the active layer is directlydisposed; means for facilitating thermal flow from an area of thestacked IC device, the thermal flow means partially disposed within thesubstrate layer and partially disposed within the active layer in whichthe active circuits are disposed.
 16. A stacked integrated circuit (IC)device comprising: first and second tiers, each of the first and secondtiers having an active layer in which active circuits are disposed and asubstrate layer on which the active layer is directly disposed; andmeans for transferring thermal energy to/from a location in at least oneof the tiers by selective application of current flow with respect tothe transferring means, the transferring means partially constructed inat least one of the substrate layers of the tiers and partiallyconstructed within at least one of the active layers.
 17. A stackedintegrated circuit (IC) device comprising: at least two bonded tiers,each tier containing an active layer in which circuit elements aredisposed and a substrate layer on which the active layer is directlydisposed; and means for facilitating thermal flow partially constructedwithin at least one of the substrate layers of the tiers and partiallyconstructed within at least one of the active layers, the thermal meansbeing configured for selectively heating/cooling a particular area ofone of the tiers.
 18. The stacked IC device of claim 1, in which thearea of the stacked IC device is a thermally troubled area.
 19. Thestacked IC device of claim 7, in which the location is a thermallytroubled location.
 20. The stacked IC device of claim 1, in which thestacked IC device is integrated into a mobile phone, a set top box, amusic player, a video player, an entertainment unit, a navigationdevice, a computer, a hand-held personal communication systems (PCS)unit, a portable data unit, and/or a fixed location data unit.
 21. Thestacked IC device of claim 7, in which the stacked IC device isintegrated into a mobile phone, a set top box, a music player, a videoplayer, an entertainment unit, a navigation device, a computer, ahand-held personal communication systems (PCS) unit, a portable dataunit, and/or a fixed location data unit.
 22. The stacked IC device ofclaim 12, in which the stacked IC device is integrated into a mobilephone, a set top box, a music player, a video player, an entertainmentunit, a navigation device, a computer, a hand-held personalcommunication systems (PCS) unit, a portable data unit, and/or a fixedlocation data unit.
 23. The stacked IC device of claim 15, in which thestacked IC device is integrated into a mobile phone, a set top box, amusic player, a video player, an entertainment unit, a navigationdevice, a computer, a hand-held personal communication systems (PCS)unit, a portable data unit, and/or a fixed location data unit.
 24. Thestacked IC device of claim 16, in which the stacked IC device isintegrated into a mobile phone, a set top box, a music player, a videoplayer, an entertainment unit, a navigation device, a computer, ahand-held personal communication systems (PCS) unit, a portable dataunit, and/or a fixed location data unit.
 25. The stacked IC device ofclaim 17, in which the stacked IC device is integrated into a mobilephone, a set top box, a music player, a video player, an entertainmentunit, a navigation device, a computer, a hand-held personalcommunication systems (PCS) unit, a portable data unit, and/or a fixedlocation data unit.